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How To Fabrication of DNV Certied Skids 2.7-1

REPRESENTING

How To Fabrication
of DNV Certied Skids
2.7-1
gregbright
July 14, 2015
Skids
2 Comments

DNV Fabrication

IncreaseddemandforfabricatedDNVskidsisbeingdriven
byqualityandsafetyconcernsforequipmentbeing
installedonanyDNVclassedvessel,includinganyoffshore
platform,marinevessel,FPSO,drillship,orothermarine
installation.Theseconcernsareatanalltimehighasa
resultoftheMacondoblowoutintheGulfofMexicoin
2010.

LARGE FORMAT
TUBE LASER
LT8 rec...

FLAT BED & 3D

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Operatingthesecomplexsystemsandfacilitiesrequires
complexfabrication.OurprincipalsDNVcertification

Housto...

proceduresassureowners,authorities,andother
stakeholdersthattheDNVclassedfacilityhascertified
equipmentaboardandcomplieswithDNVclassification
rulesandrequirementsindependentoflocation.
ClassingSocietiesandtheIMO
IMOistheInternationalMaritimeOrganizationanditisthe
UnitedNationsagencyresponsibleforthesafetyand
securityofshippingandthepreventionofpollutionbyships.
TheIMOisthestandardsettingauthorityforthesafety,
security,andenvironmentalaspectsofinternational
shipping.Itcreatesaregulatoryframeworkfortheshipping
industrythatisuniversallyadopted.

CATEGORIES
Select Category

TheIMOhasadoptedstandardsforotherrecognized
organizationsliketheDNVwhicharecalledclassification
societies.

RECENT POSTS

AtOceanFab,safety,quality,theenvironment,and
compliancewithDNVstandardsareournumberone
concern.InordertogainDNVemblemsforanyskidded

SubSea Wye Skids

Controls Mudmat
Quayside Barge

equipment,anumberofapprovalandcertification
proceduresmustbefollowed.Ourprincipalshavemany

Loadout

yearsexperiencewithcomplexfabrications,including
subseaandoffshore/topsidefabrication.
DNVhastraditionallybeenmorepopularinEuropean
waters,butsinceithasbecomethenumberoneclassing
societyintheworld,moreandmoresupermajoroil
companiesandoperatorsarerequiringthatanyequipment
goingonaDNVClassedOffshoreInstallationgoing
anywhereintheworldbecomecertifiedbyDNV.Whether
itsatemporaryorapermanentinstallationfixedor
floatingoffshoreinstallations,ships,drillrigs,production
rigs,oroffshorevessels,includingfloatingplatforms.This
equipmentcanincluderentalequipment,skidded

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equipment,shippingcontainers,seacans,frames,structural
steel,twistlocks,seafasteningclips,deckfastening,waste
skips,tanksthelistgoesonandon.

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*Disclaimer:OceanFabnoritsprincipalsareinanyway
affiliatedwithDNVGL.DNVregulatesalloftheprocesses

OceanFab

listedbelowforDNVcertification.Theseareonlyhistorical
examplesoftheprocessesthatwehavegonethroughwith
DNV.DNVwillbethefinalauthorityforanyprocess,
includingnewonesthatOceanFabsprincipalshaveto
certifyforourclients.TheruleschangefrequentlyPlease
consultyourlocalDNVofficeformoredetails.OceanFabis
notanengineeringcompanyhowever,ourprincipalscan
provideengineeringservices.
QualityControlOceanFabprincipalsQuality
ManagementSystemensuresthequalityofproceduresand
facilitiesbyimplementingaQMSinaccordancewithISO

PromoteYourPageToo

9001.QMSauditsandapprovalbytheDNVclassification
societyverifythatourQMSmeetsthehighstandardsand
arequalifiedtomanufactureskidsaccordingtothoseDNV
standards.
Witnessing
Witnessingisalargepartofthecertificationprocessfor
DNV.ADNVsurveyorwillneedtowitnessnumerous
aspectsintheprocessofcertificationincludingtheweld
procedureapproval,welderqualification,theweldstartupof
eachspecificproject,andduringvariousmilestonesinthe
projectaccordingtotheQualityInspection&TestPlan.
DNVSurveyorswillcomeandinspect/witnessatdefined
inspectionpoints.
1.Couponwitnessingonceourwrittenweldprocedure
hasbeenapproved,aDNVsurveyormustcometoour
facilityandwitnesstheweldingoftestcoupons.
2.WelderQualifying
3.StartUp
4.MillstoneauditsaccordingtheQualityInspection&Test
Plan.
5.Inspectionoftheprototypeandtheprototypeisalso
tested

THREE MOST COMMON DNV STANDARDS

FOR DNV CLASSED OFFSHORE
EQUIPMENT

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Thethreemostcommonstandardsrelatetoaportable
offshoreunit,andusuallyinvolvesometypeofLifting
Operationeitherfromthedocktothevesselorliftingon
theopenseas.Thestandardsapplytoanyfabricated
enclosureorskidforoffshorevesselsandmarine
applications.Theyinclude:
DNVStandard2.71*OffshoreContainers(appliesto
skids,frames,enclosures,etc.)standardforcertifying
offshorecontainertransportunitsandproducedbya
privatelyheldcompany.AsdefinedbytheInternational
MaritimeOrganization,anoffshorecontainerisaportable
unit,speciallydesignedforrepeateduseinthetransportof
goodsorequipmentto,fromorbetweenfixedand/or
floatingoffshoreinstallationsandships.
Offshorecontainersarealsocommonlycalledskidsinthe
offshoreoilandgascommunity,astheyareoftenusedto
transportlargecomponentstodrillingandproductionrigs.
Thesecanbeassimpleasframesthatholdthecontents.
Theskid,alongwithitscontents,issometimesreferredto
asaskidpackage.Thethreetypicalphasesoftransport
are:shoreside(e.g.byforklifttruck),bysupplyvesseland
liftingtoandfromoffshoreinstallations.TheStandardfor
Certificationincludesdesignrequirementsrelatedtoall
threephases.Therequirementsfordesign,testingand
productionofoffshorecontainersinEN12079aredirectly
basedonDNVStandardforCertification2.71

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DNVStandard2.72OffshoreServiceModules
Offshoreservicemodulesareoftendesignedtoperform
temporaryservicesoninstallations/vesselsandtherefore
maybemovedamongdifferentoffshoreinstallations/units
andintodifferentnationalwaters.
DNVStandard2.73PortableOffshoreUnitscoversall
othertypesofportableoffshoreunits,otherthanoffshore
containers.Thestandardisbuiltonthe2.71DNV
Standardandusuallyinvolvesliftingoperationswhileonthe
openseasversussimplyloadingandunloadingfromthe
dock.
Note:Itsimportanttonote,thatwhileDNV2.71most
commonlyreferstothetermshippingcontainerThis
standardalsocoversSkiddedEquipment,DNVBaskets,
MudSkips,CuttingBoxes,WasteSkips,Enclosures,and
Tanks.Thesecanbeassimpleasframesthatholdthe
contents.Theskid,alongwithitscontents,issometimes
referredtoasaskidpackage.

DNV PROJECT TIMELINE AND

SCHEDULING
Becauseofthelargeamountofpaperwork,scheduling,and
witnessinginvolvedforfinalDNVcertification,itis
paramountthatweworkwithinourclientsexpectationsfor
scheduling.OceanFabsprincipalshaveyearsof
experiencewiththisprocessandhavedeveloped
relationshipswithlocalDNVsurveyorsandotherDNV
administrationtofacilitatethisprocessandkeepeverything
onschedule.
ForDNVapprovalandcertification,therearefivebasic
steps:
1.Certificationofour(orourclientspecified)writtenWeld
Procedure,LabTests,andWelderQualification
2.Appraisalandapprovalofourprincipalsequipment/skid
/framedesign
3.Audit/surveyduringtheinitialweldingStartUp
4.ProductionAudit/surveyduringthemanufacturingof
theequipment
5.TestingoftheprototypeForTypeApproval(Type

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approvalmeansthereareaseriesofthesameunitsbeing
manufacturedoveraperiodoftime)
Note:ItsimportanttonotethatDNVcertificationisproject
specific.Inotherwords,eachnewfabricationorderweget
fromourclienthastogothroughanewDNVapprovaland
certificationprocess.Evenifitisarepeatorderforthe
sameexactproduct.Insomecircumstancesitisadvisable
togetaseriesofthesamemanufacturedproductapproved
byDNVForrepeatproductswhichfallunderamore
manufacturingmodeofconstructionwecangetDNV
surveyorstoapproveaTypeApproval.
Step#1DNVWeldProcedureApproval
TheSurveySubmitOurWrittenWeldProcedureWPS,
PQR,andlabtestspecifications/planforReview&
ComplianceQualifythewelders.
Theveryfirststepofthesurveyprocessistosubmitour
writtenWPS(WeldProcedureSpecification)andPQR
(ProcedureQualificationRecord)forDNVapprovalforanin
houseweldingprocedure.Thispaperworkoutlinesthe
detailsofwhatneedstobeaccomplished,thepurpose,the
inspectiontestprogram,andwhatisrequiredfromDNV.
WesubmitWPS,PQRs,andLabTestingSpecstoaDNV
WeldingEngineerforreview.OncetheWeldingEngineer
givesapproval,wescheduleaDNVSurveyortobeatour
facilitytowitnesstheweldingofthecoupons.
Theinspectiontestprogramincludes:Verificationand
testingofmaterialsWelderQualificationAcceptanceof
weldproceduresAcceptanceofNDEprocedures
WitnessandacceptanceofprototypetestingVerification
ofidentificationandmarking.
Variables/Parameters:WeldingProcesses,JointDesign,
Positions,FillerMaterial,ElectricalCharacteristics,Heat
(AmpsxVoltsx60/TravelSpeed),Technique,Preheat
interpassandPostweldheattreatment,Shielding,Initial
andInterpasscleaning/grinding
LabTestingOutlineCouponTestingSpecifications
VisualTesting
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UltrasonicTesting
MagneticParticleTesting
SideBends
ReducedSectionTensionTests
AllWeldMetalTensile
CVNTests(CharpyVNotchtests)Specimenswithvarious
notches
HardnessTestVickersHv10
Macros(photographsincluded)
Wethenweldthecouponsandrecordtheinformation.All
testweldsarewitnessed,prepared,welded,andtestedin
conformancewiththerequirementsofthespecified
StructuralWeldingCode.
Uponcompletionoftheweldcouponsweshipthecoupons
tothetestinglabtobetested.LabTestingmustbe
witnessedbyDNV.
Afterthelabtestshavebeenwitnessedandapproved,we
thewritethelabresults/parametersintotheWPS/PQRs,
thensubmitthosedocumentsbacktoDNVforthefinal
approvalstamping.TheupdatedPQRsandWPSwillbe
basedonthesupportingdataandlabresults.DNVwillthen
doafinalreviewandeitherprovideDNVapprovalorany
suggestedchanges.
Oncelabtestingresultsarereceivedbackatourfacility,we
finishfillingouttheWPSpaperworkwiththeinformation
providedbythePQRs.Finally,wesubmitthecompleted
WPS,PQRsandlabtestingresultstoDNVWelding
Engineerforweldprocedureapproval.
Whenfinallyapproved,wegiveaDNVSurveyorthe
opportunitytocomeouttowitnessthequalificationofour
welderstothenewweldprocedure.
Thisapprovalisspecifictoourcompanyandwitnessedby
DNV.OceanFabsprincipalshavebeenapprovedfor
numerousweldingprocedurebymanyoftheclassing
societies,includingABSandDNV.Oftentimeswecan
submitoneofourexistingweldingprocedureswhichhas
alreadybeenapprovedbyanotherclassingsocietyand
DNVwillallowustouseit.However,anyexistingwelding

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procedurestillhastogothroughthepropercertification
withDNVforapprovalandcertification.

Step#2EngineeringandDesignoftheDNV
Equipment/Structure
Ourprincipalssubmitthestructuraldesignoftheoffshore
skiddedequipmentwhichmustbereviewedandapproved

byDNV.Thedesignapprovalprocessassuresthatthe
designoftheequipmentwhichistobeinstalledonaDNV
classedvesselcomplieswiththeDNVrules.Thisisthe
beginningoftheprocesstoassurethatthefabricated
equipmentsatisfiesDNVsrequirements.
TheDesignapprovalincludesaninitialreview,theissueof
comments,andareviewofnextdocumentrevisionsto
confirmincorporationofDNVcomments.Duringthedesign
approvalprocess,ourprincipalscanprovideapproved
engineereddrawings.Thisprocesscantake6to8weeks.
DesignReviewOptions:
CaseApprovalforoneoffpiecesofequipmentorsmall
productionruns.
Casebycaseapprovaltendstobejobspecificforaknown
batch(customerpurchaseorder)andonlyvalidforthat
batch.
TypeApproval
Ifourclientneedstomanufactureseveralunitsovera
periodoftimeaTypeApprovalisrequestedfromDNV.This
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isonlyvalidforcertaintimeframesandmustberenewed
periodically.
Ourprincipalssubmitthefollowingdocumentationfor
DesignReview:
Thecontainersstructuraldrawingsarereviewedaccording
tothestandardsreferencedinIMOMSC/Circ.860.Details
ofthematerialsandstrengthofthecargocontainment
structure,aswellastheliftingandsecuringarrangements
areappraised.Drawingsmustshow:Dimensionsand
loadratingsMaterialspecificationsDetailsofwelding
methodsandweldsizesDetailsofanyotherfastening
methodsDetailsofanyspecialtreatmentformaterials
DetailsofsealantmaterialsDetailsofcornerfittingsand
closuremechanisms,togetherwithname(s)ofthe
manufacturer(s)ofthesepartsMandatorymarking.

Thedesignmustalsoconsiderallofthevarious
componentsandforcessubjectedtotheequipmentskid:
Forexample,thesteel,stabilityagainsttipping,Design
Temperature,AllowableStresses,Liftingwiththelifting
set,Designofliftingsets,Liftingwithforklifttruck,
HorizontalImpact,VerticalImpact,Containerwalls,
Minimummaterialthickness,Welding(someweldsarefull
penetrationweldsandothersarefilletwelds),Floor
(drainage),Doorsandhatches,Intermediatecargodecks,
Internalsecuringpoints,Forkliftpockets,Padeyes,
PrototypeTesting,Coatingandcorrosionprotection,
Dimensionsandstrengthofliftingsets,weights,andsling
anglecalculations.
Step#3TheStartUpforaSpecificUnitofDNV
CertifiedEquipment
OnceDNVapprovesourDesignandWPS,thenextstep,
beforewebeginwelding,istoscheduleDNVtowitnessa
weldstartup.Thisneedstobedoneoneachnewseries
(purchaseorder),evenifitsthesamerepeatitemsthat
wasmadebefore.
AtthistimeDNVcanalsoqualifyadditionalweldersand
beginlayoutforDNVwitness/auditofthestartup.Only
afterfinalapprovedcertificationandindividualwelder

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qualificationarewereadytofabricateandscheduleaDNV
surveyorforaweldstart/audit.
Formultipleitemswhereourclientsneedtomanufacture
severalunitsoveraperiodoftimeaTypeApprovalis
requestedfromDNV.ForTypeApprovalTheDNV
surveyorwillusuallyauditmoreofteninthebeginninguntil
theyrecomfortablewithourQMSfortheproject,thenitwill
diminishandbecomerandom.
Wecommunicateschedulemilestonestoallpartiesaswe
goalongwiththeproject.
Duringfabrication,welderIDstampsarestampedoneach
weld.WeprovideaWeldMaporwrittenrecordofwhich
welderweldedwhatpartoftheassembly.
Step#4ProductionoftheDNVEquipment

Duringtheproductionphase,DNVwillperiodicallyvisitour
facilityandaudittheprocessduringmanufacture.The
frequencyoftheauditsdependsonhowcomfortablethey
arewithourqualityprocesses,proceduresandadherence
tothedesignandtheQualityInspection&TestPlan.
ProductionInspectionTheDNVsurveyortypicallyuses
thefollowingcriteriawheninspectingduringtheproduction
phase.
Dimensionalcontrol
Visualinspectionofweldpreparation,welding,
alignment,materialmarkingetc.
Reviewofmaterialcertificates
ReviewofWPS/WPQ,WeldersQualificationTests,
weldingconsumables
Reviewofequipmentdocumentationasnecessary
ReviewofNDEdocumentationandreport
Reviewofthemarking
ProductionDocumentationGeneralProductionis
performedaccordingtoapproveddrawings,specifications
andprocedures.Wemustsubmitourqualityplanfor
acceptancebeforeproductionstarts.Thecertificationof
eachcontainerisbasedonthefollowingdocumentation,
whichweretainforthetimeperiodspecifiedbyDNV.
Approveddrawings,includingageneralarrangement
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drawing
Structuralcalculations
Typeapprovalcertificate(whererelevantonlyfor
multiplerepeatunits)
Materialdocumentation
Weldingprocedurequalifications(WPQ)
Weldingprocedurespecifications(WPS)
Weldersqualificationcertificates
WeldMap(writtenrecordofwhichwelderweldedwhat
partoftheassembly)
Reportontraceabilityofmaterialsintheprimary
structure
Reportfrommanufacturinginspection
Reportfromdimensionalcontrol
Reportfromnondestructiveexamination(NDE).
Reportfromprototypetesting
Reportfromproductiontesting
Reportfromfinalinspection.

MarkingsDuringproduction,andonthefinishedproduct,
weidentifythematerialsusedfortheprimarystructurewith
thecorrespondingdocumentation.Whenmarkingsarenot
visibleonthefinishedproduct,weprovidealogofthe
componentstoidentifyandensuretraceabilityofthe
materials.
InspectionofWeldsInspectionofWeldsWeldsare
subjecttovisualinspectionandNDE.Allweldsare100%
visuallyinspectedunlessotherwiseagreedinanMSA.
Step#5TestingoftheDNVEquipment
Typeapprovaloftheequipmentfirstinvolvesthe
constructionandtestingofthefirstarticleorprototype,built
accordingtotheapproveddrawings.Itmustalsousethe
samematerialsasproposedfornormalproduction.Tests
include:FourpointliftusingallpadeyesTwopointlift
testusingopposedpadeyesAverticalimpacttestAtilt
testTanksfordangerouscargoesshallinadditionbe
testedwithalltherequirementsoftheIMDGcode.
DNVEmblemOncetheDNVsurveyorhascompletedthe
manufacturinginspection,witnessedtestingandreviewed
theproductiondocumentationaCertificateforOffshore
Container(FormNo.49.07a)willbeissued.Thenumbered
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DNVemblemforoffshorecontainers(orskid/frame)will
beaffixedtothecontainer(orskid/frame).Theauthorized
DNVsurveyorwillhardstampandthecertificatenumber
intothebottomframebelowtheemblemorinothersuitable
locationontheprimarystructureneartheemblem.

CERTIFIED WELD PROCEDURES

QUALIFIED WELDERS CERTIFIED
DESIGN
ProcedureAprocedureisthedescriptionofthe
technique(method)adoptedtopreformqualityweldingas
requiredbytheapplicablecode.Theproceduremustbe
qualifiedagainstthecertainstandards(Codes)
AWSD1.1
DNV,StandardforCertificationNo.2.22Lifting
Appliances,
DNV,StandardforCertificationNo.2.71Offshore
Containers,
DNV,StandardforCertificationNo.2.73Portable
OffshoreUnits,
WelderThecontractor(thefabricationshop)istheentity
qualifyingtheweldprocedureitself,theindividualwelderis
notcertifyingtheproceduretheyareonlybeingqualified
toweldaccordingtotheprocedure.
Wemustcertifythatanyofourweldersweldingtothe
previouslyqualified(inhouse)specificationhavebeen
testedandarequalifiedtopreformthatweldprocedure.
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TheweldersQualificationTestSheetsandWelder
QualificationTestRecordmustbeavailable,attestingto
theirabilitytoweldinaccordancetoourWeldingProcedure
Specification.
DesignThestructuraldesignoftheoffshoreskidded
equipmentisprovidedbyeitherourclientsorprincipals.
Whoeverisresponsibleforthedesign,thedesignmustbe
reviewedandapprovedbyDNV.Thedesignapproval
processassuresthatthedesignoftheequipmentwhichis
tobeDNVclassifiedcomplieswiththeDNVrules.Thisis
thebeginningoftheprocesstoassurethatthefabricated
equipmentsatisfiesDNVsrequirements.

SPECIAL THANKS TO TREX GRAPHICS

AND ANIMATIONS
GraphicimagesourceTREXGraphicsandanimations.
Asanaddedvalueservice,TREX3Ddesignsallowclients

theabilitytoutilizeTREXscalemodelsofaDNV
equipmentplacementtomoreeasilynavigatecomplex
DNVvessellayouts,effectivelyallowingoperatorsthe
capabilitytosafelyplacetheequipment(virtually)before
actualequipmenthadbeeninstalled.
TREXworkhasbeenfeaturedinE&PMagazineaswellas
numerousotherindustrypublications.
TREXsrenderfarmfacilitatesthemassiveamountsof
parallelprocessingrequiredtogenerate3Danimations.
Currently,150CPUCoreshavebeencreatedandare
continuouslybeingaddedtoshortenrendertimes.
Whetherwecreategraphicsforthefabricatedequipment
weconstructforyou,oryourinhousefabricatedequipment
theanimationseffectivelyillustratetoclientshow
structuresareinstalledandmaintained.Wealsohavea
widerangeofstructuralandpipingmodels,developedinto
afullyproduced3Dartisticrenditionreadyforcomputer
simulation.
Ourclientscanalsobenefitfromhavingtheirconceptual
ideasillustratedandprintedaslargeformatgraphicposters
andinteractivePDFsasprojectsarebeingdeveloped.
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Our3Dmodelscanprovidefullfunctionalityofmovingparts
andassemblies,exactbillofmaterials,weights,centerof
gravityofcomponentsandassemblies,and2D+3Dcad
drawings.
3DmodelscanalsobeusedinthedevelopmentofFATand
SITlayout,procedures,equipmentaccessibility,
transportationloadout,testingandtraining.Design
packagesinclude:StillImages|Animations|Video

*Disclaimer:OceanFabnoritsprincipalsareinanyway
affiliatedwithDNVGL.DNVregulatesalloftheprocesses
listedaboveforDNVcertification.Theseareonlyhistorical
examplesoftheprocessesthatwehavegonethroughwith
DNV.DNVwillbethefinalauthorityforanyprocess,
includingnewonesthatOceanFabsprincipalshaveto
certifyforourclients.TheruleschangefrequentlyPlease

consultyourlocalDNVofficeformoredetails.OceanFabis
notanengineeringcompanyhowever,ourprincipalscan
provideengineeringservices.

About The Author

Gregbright

2 Comments
Choteanan Ch. FEBRUARY 25, 2016

Dear Sirs,
Could you suggest how to become a
fabrication approved and certied by DNV?

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Best regards,
Choteanan Ch.
Reply

gregbright MARCH 2, 2016

Dear Choteanan Ch. Yes, we

can provide DNV certied skid
fabrication services to you. Do

you need DNV certication in

Thailand, or in Houston, Texas?
Reply

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